Packaging system

ABSTRACT

A method and apparatus for packaging products in containers while the containers are continuously moving along a path is disclosed herein. The containers are sequentially dropped from a nested stack towards an apertured conveyor that defines the path for the containers and a negative pressure is produced below the conveyor to assist in drawing the containers into the apertures of the conveyor. The conveyor moves the containers to a filling station where the product is flowed into the containers at several different locations, so that the containers are filled in stages while being moved by the conveyor. The filled containers then progress to a cover applying station and are preferably arranged in at least a pair of rows with a continuous web of heat sealable cover film heat sealed to the filled containers at the cover applying station. 
     In one embodiment, the continuous web of material is then severed longitudinally and transversely between each adjacent pair of containers to produce rectangular covers and the periphery of the covers are folded under the rim of the container by automatic folding means. 
     In another embodiment, the web is only partially severed between groups of containers while the web in the remaining areas forms an interconnection between adjacent containers and the severed portions of the webs are folded downwardly to produce an interconnected group of filled containers. 
     In both embodiments, the apparatus includes novel heating and pressure applying means for sealing the web to the container rims and simplified structure for severing the webs at selected locations. The severing mechanism produces individual separated containers, each having four gripping tabs on the cover, in one embodiment while producing interconnected groups of containers in the alternate embodiment with each container having four gripping tabs on the cover.

This is a continuation of application serial no. 282,758, filed Aug. 22,1972, now U.S. Pat. No. 3,838,550.

BACKGROUND OF THE INVENTION

Individual sealed containers in various sizes, shapes and forms havebecome increasingly popular in packaging numerous products, particularlyof the flowable type.

Special types of packaging equipment have been developed that arecapable of taking containers from a stack and transferring them to aconveyor which moves the containers along a predetermined path. Thecontainers are then filled at a filling station and subsequently coversare applied to the respective containers at a cover applying station.

Heretofore, most of the machinery that has been developed for performingthe above functions has been extremely complex and had to be operated onan intermittent basis, which substantially restricted the output of theequipment.

While some machines have been proposed which are capable of operating acontinuous basis in filling and covering containers, the arrangement ofthe various stations still restricts the speed at which the machinerycan be operated.

SUMMARY OF THE INVENTION

The present invention embodies a new concept of packaging flowableproducts in containers and sealing the containers, and the variousstations for performing separate functions are designed with a viewtowards maximizing the output of the unit. More specifically, each ofthe various stations is designed to reduce the time required forperforming the particular function without sacrificing reliability ofthe overall system.

The method of the present invention contains a novel system for insuringthat containers are removed from a nested stack and properly positionedon a continuously moving conveyor in a minimum period of time. Thefilling station for placing the flowable product into the containers isdesigned to fill the container in separate stages to further enhance theprimary purpose of increasing the productivity of the machine.

In one embodiment, the method also contemplates simultaneouslyprocessing a plurality of containers in separate rows and automaticallysealing and folding the covers to a final configuration in a simple andefficient manner. In an alternate embodiment, a continuous web ofmaterial is utilized for covers for a plurality of longitudinally andtransversely spaced containers and the containers are interconnected atspaced locations by selectively severing and folding certain portions ofthe endless web. Again, this is accomplished by automatic means that iscapable of performing the function at an extremely rapid rate.

The apparatus for performing the above method consists of an endlessapertured conveyor that is capable of receiving the plurality of rows ofcontainers for movement along a path from a nested stack at thedispensing station. A vacuum motor produces a negative pressure belowthe openings in the conveyor at the dispensing station to reduce thenecessary time required for moving the containers from the stack intothe openings in the conveyor. The filling of the containers in stages isaccomplished by separate filling nozzles that are longitudinally spacedalong each row of containers and each nozzle partially fills eachcontainer in the row as the container is continuously moving along thepath.

The means for applying closures or covers to the respective containers,consists of a continuous web of foil that has heat sealingcharacteristics thereon with means for heat sealing the surface to theadjacent surface of the rims of the containers and in one embodiment,the continuous web is then severed longitudinally and transversely toproduce rectangular covers on each of the containers with the peripheryof the covers extending beyond the periphery of the rims of thecontainers. In this embodiment, the portions of the covers extendingbeyond the periphery of the rim are then initially folded downwardly ata first folding station while the containers continue their movementalong the path and subsequently pass between means that further foldsthe peripheries of the covers into engagement with the sides of thecontainers. Each corner of the cover defines a gripping element that maybe used to ultimately remove the cover from the container.

In an alternate embodiment, at least two rows of containers aresimultaneously processed and the web of material is of a width slightlygreater than the width of the two rows of the containers. In thisembodiment, the mechanism for applying the covers also includes severingmeans that sever only selected portions of the cover between theadjacent containers while maintaining a connection between thecontainers through the cover web. The severed portions are then againfolded downwardly to provide gripping elements for ultimately removingthe covers.

BRIEF DESCRIPTION OF SEVERAL VIEWS OF DRAWINGS

FIG. 1 is a perspective view of a filled and sealed container;

FIG. 2 is a side elevation view of the machine that accomplishes theautomatic dispensing, filling and covering of the container shown inFIG. 1;

FIG. 2a is a fragmentary plan view of the vacuum applying means in thedispensing station;

FIG. 3 is an enlarged perspective view of the filling station for themachine shown in FIG. 2;

FIG. 4 is an enlarged vertical section of the cutting means forming partof the cover applying mechanism with the section taken generally alongline 4--4 of FIG. 5;

FIG. 5 is a transverse section taken along line 5--5 of FIG. 6;

FIG. 6 is an enlarged perspective view of the severing station of themachine;

FIG. 7 is an enlarged fragmentary sectional view as viewed on line 7--7of FIG. 6;

FIG. 8 is an enlarged vertical section through the cover applyingstation shown in FIG. 2;

FIG. 9 is a section as viewed along line 9--9 of FIG. 8;

FIG. 10 is an enlarged sectional view through the first folding stationfor folding the covers with respect to containers;

FIG. 11 is a sectional view as viewed along line 11--11 of FIG. 10;

FIG. 12 is a schematic illustration of three stages or positions for thefirst folding mechanism shown in FIG. 10;

FIG. 13 is an enlarged fragmentary perspective view of the secondfolding station in the machine of FIG. 2;

FIG. 14 is a section taken generally along the line 14--14 of FIG. 13;

FIG. 14a is a fragmentary view similar to FIG. 13 showing therelationship of the container with respect to certain elements in thesecond folding station;

FIG. 15 is a plan view of a slightly modified form of container andcover group (before folding the cover) capable of being produced withthe machine, in modified form, shown in FIG. 2;

FIG. 16 is a side elevation of the containers and covers with the coversin their final folded position;

FIG. 17 is a view similar to FIG. 6 showing a modified form of cuttermeans utilized for producing the product shown in FIG. 16;

FIG. 18 (appearing with FIG. 6) is an end view with certain parts brokenaway of the first folding station for producing the alternate form ofthe container and cover arrangement shown in FIG. 15;

FIG. 19 (appearing with FIG. 6) is a section as viewed along line 19--19of FIG. 18;

FIG. 20 (appearing with FIG. 6) is a view taken along line 20--20 ofFIG. 18 with the containers being deleted.

DETAILED DESCRIPTION

While this invention is susceptible of embodiment in many differentforms, there is shown in the drawings and will herein be described indetail several embodiment, with the understanding that the presentdisclosure is to be considered an an exemplification of the principlesof the invention and is not intended to limit the invention to theembodiments illustrated.

GENERAL PACKAGING SYSTEM

The overall packaging apparatus of the present invention is illustratedat 30 in FIG. 2 and includes a common drive mechanism (not shown) fordriving all of the moving parts of the apparatus. The apparatus ormachine 30 includes endless driven conveyor means 32 that defines a pathfor a plurality of containers 34 which are supplied to the conveyor at adispensing station 36. After the containers have been inserted into theapertured conveyor (to be described later), the containers are movedpast a filling station 38 where flowable product is placed into thecontainers while they are being continuously moved along the path byconveyor means 32. The filled containers are then moved to a coverapplying station 40 where a continuous web of cover material is heatsealed to the containers. The cover applying station 40 alsoincorporates a cutting station 42 where the continuous web of materialapplied to the containers is severed into individual covers andthereafter the covers are folded with respect to the container at afirst folding station 44 and a second folding station 46 and exit fromthe apparatus at 48 to a further conveyor 49 for future packaging andshipment.

THE PACKAGE

The completed package 50 is shown in FIG. 1 and consists of container 34that has a circular bottom wall 54 and circular side wall 56 extendingupwardly therefrom with a circular rim 58 extending outwardly from theupper end of the side wall. Container 34 may be formed of any suitablethermoplastic material by conventional techniques well understood tothose skilled in the art, and the side wall may be ribbed (asillustrated), smooth, plain, or decorated, as is also well understood inthe art. The container rim 58 defines a generally flat upper surface 60(FIGS. 3 and 6) upon which a cover consisting of a rectangular flexiblesheet having heat sealing characteristics on at least one surfacethereof is sealed to the flat upper surface. Since one of the primaryuses of containers 34 is in the packaging of liquids, the seal betweenthe cover and container rim is effectively circumferentially continuousand leakproof. The cover is preferably formed of a material that willtake on a permanent set when folded on bent, and a metallic foil such asaluminum is well suited for the purposes of the present invention. Thefoil may be coated, or otherwise suitably treated, on the side facingthe container rims with a heat sealable substance that is compatablewith the material from which the containers are made. The presentinvention also contemplates that a layer of heat sealable material maybe laminated to a carrier foil, and that the cover may be formedentirely of an inherently heat sealable material, such as athermoplastic sheet. The term "film" as used herein and in the appendedclaims is intended to cover all such examples of cover materials. Therectangular, flexible foil sheet, which is preferred because of itsability to take on a permanent set, has a peripheral edge 64 thatextends beyond the rim 58 and is tucked or folded under the rim. Therectangular sheet defines four corners 66 (only two being shown inFIG. 1) that extend substantially below the rim and each corner definesa gripping mechanism for removing the cover from the container to allowremoval of the contents.

It will be appreciated that the particular configuration of the coverstructure for the container which results in four gripping portions ortabs is of considerable benefit in this field. Because of thecharacteristics of the aluminum foil thaat is utilized for the coverstructure, in many instances, where a single tab is provided forremoving the cover, the foil may tear during removal resulting inconsiderable difficulty in removal of the portion of the foil thatremains on the container. However, with four tabs as shown in thecontainer of FIG. 1, the entire cover, even when portions thereof aresevered during removal, can be removed by grasping the appropriatenumber of tabs.

CONVEYOR MEANS

Before describing the conveyor means 32, it should be noted that thepackaging apparatus 30 illustrated in the drawings is specificallydesigned for simultaneously processing a plurality of rows of containersand two such rows have been shown for purposes of illustration. However,any greater or lesser number of rows could readily be incorporated intoa machine or apparatus of the type disclosed without departing from thespirit of any of the various aspects of the invention.

Conveyor means 32 (FIG. 13) consists of a pair of endless chains 70 witheach chain 70 entrained over a drive sprocket 72 (FIG. 2) and a drivensprocket 74 respectively supported on shafts 76 and 78 located adjacentopposite ends of the packaging apparatus. Each chain 70 (FIG. 13) has aplurality of studs 80 extending upwardly therefrom at spaced locationswith each stud having an enlarged button 82 at the upper end thereof.

A plurality of plates 84 extend between the respective chains 70 andhave recesses 86 on opposite ends thereof which are adapted to receivethe studs 80 and the apertured recesses are smaller than the enlargedbuttons 82. In this way, the respective plates can readily be insertedby transverse deflection of the chains and forcing the studs 80 into therecesses.

Each of the plates 84 has first and second pairs of semi-circularrecesses 88 extending from opposite side of the plate. Two of suchrecesses in adjacent pairs of plates 84 define openings or apertures 89for receiving the respective containers, as will be described later.

CONTAINER DISPENSING STATION

The container dispensing station 36 is most clearly shown in FIGS. 2 and2a and consists of first and second storage compartments 100 for storingfirst and second groups of nested open topped rimmed containers 34. Thelower ends of the respective compartments have container releasingmechanisms 102, each of which consists of a hub 104 having an internalretaining mechanism (not shown) that normally holds all of thecontainers in the stack. A releasing rod 106 extends from each of themechanisms 102 and rod 106 is connected to one end of a lever 108pivoted intermediate its ends at 110 on a support 111. The opposite endof the lever 108 is connected to an actuating rod 112 which has aconnection 114 at its opposite to driven member 116. Driven member 116is rotated by the drive mechanism (not shown) so that a pair ofcontainers 34 are simultaneously released form the respective stacks insynchronized relation with the movement of conveyor means and fall bygravity towards openings 89 defined in conveyor means 32.

Since the dispensing mechanism is commercially available and forms nopart of the present invention, a further detailed description thereofdoes not appear to be necessary.

As was indicated above, the entire packaging apparatus is designed forincreasing the productivity of the machine without sacrificingreliability and operational efficiency.

In order to increase the speed at which the machine or apparatus 30 maybe operated, dispensing station 36 includes novel apparatus fordecreasing the time required for the containers to be deposited into theopenings 89 after they have been released from the respective stacks.For this purpose, dispensing station 36 also includes means forproducing a negative pressure below the stacks of nested containers topositively draw the containers into the openings 89. This means is mostclearly shown in FIGS. 2 and 2a and consists of a vacuum pump 120 whichhas first and second conduits 122 connected thereto. The other ends ofthe respective conduits 122 are connected to vacuum chambers 124 andeach vacuum chamber consists of a tray having a flat bottom wall 126which has an opening 128 to which the conduit 122 is connected. Thevacuum chamber 124 further has an upwardly and outwardly inclined sidewall 130 which extends from the sides and rear of the flat bottom wall126. The chamber 124 is open at the top and the end extending toward theexit end of the apparatus.

With the arrangement described, a negative pressure will be developed ineach of the vacuum chambers 124 and will positively draw the containersinto the opening 89 in the conveyor after they have been released fromthe respective stacks. The vacuum chambers considerably reduce the timerequired for placing the containers in the openings, thereby allowingthe machine to be operated at a greater speed.

FILLING STATION

The filling station 38 is likewise specifically designed to increase thespeed at which the machine or apparatus may be operated. The fillingstation 38 is most clearly shown in FIG. 3 and consists of a pluralityof filling means 130 that are longitudinally spaced along the path andeach filling means partially fills each container moving along the pathso that the containers are filled in steps or stages as they are movingalong the path.

Each filling means 130 consists of a fixed bracket or support 132 thathas a plurality of nozzles 134, one for each row of containers, securedthereto and each nozzle 134 is connected to a manifold (not shown) thathas a suitable product supplied thereto from a pump (not shown). Thematerial supplied through each nozzle 134 is again supplied insynchronized relation to the movement of the containers so that eachcharge is released while the container is under the nozzle.

Thus, as the containers are moving along the path defined by conveyormeans 32, a partial charge of material is placed into the respectivecontainers by each of the filling means. For example, the presentinvention is specifically illustrated in packaging individual portionsof liquid such as fruit juice, milk or any other flowable products and,in the illustrated embodiment, two filling means are illustrated witheach filling means placing a partial or one-half of the amount offlowable product or liquid that is to be placed into the containersduring the filling process. However, it will be appreciated that anynumber of such partial fillings may be utilized to increase the speed ofthe packaging apparatus. For example, four such filling means could belongitudinally spaced along the path and each of the filling means wouldbe placing a 1/4 charge of liquid in the containers. Again, aspreviously noted, this could simultaneously be done at four differentpositions along the path and the liquid or material could be suppliedfrom a common manifold that would be simultaneously supplying thematerial to all of the hoses 136.

It will be appreciated that the plural filling means in the fillingstation have considerable advantage over a single filling means. In asingle filling means, the speed of the conveyor means is limited to theamount of time required for placing a product from a fixed source intothe container which, when moving at a continuous rate, is only under thesingle nozzle a short period of time. However, with the filling stationdescribed, the speed of the conveyor means for the containers can beincreased in multiples, determined by the number of nozzles utilized ineach row of containers.

COVER APPLYING STATION

The cover applying station 40 is most clearly shown in FIGS. 2, 8 and 9and incorporates novel mechanism for heat sealing the over structure 62to the rims of the containers. A continuous web 144 of foil having heatsealing material on one surface therof is supported in a form of a roll140 on a shaft 142 that is rotated on the housing for the packagingapparatus 30. The continuous web 144 of foil is entrained over heatingmeans 146 which acts as a guide for the web and also incorporates meansfor securing the web to the upper surface 60 of the container rim 58.When indicia is provided on the fooil, suitable means may be providedfor insuring that the indicia are in registration with the individualcontainers, as is well understood in the art.

The novel heat sealing means 146 is shown in detail in FIGS. 8 and 9 andconsists of a fixed circular drum 150 that is supported on an uprightmember 152 through elements to be described later. The hollow fixedcircular member has a plurality of openings 154 at circumferentiallyspaced locations and each opening 154 receives a heating element 156.The plurality of heating elements extend beyond the drum and are fixedlysecured to the upright 152 through nuts 158 so that the heating elementsact as the support for maintaining the drum 150 in a fixed positionabove the path defined by conveyor means 32. While four such heatingelements 156 have been shown in FIGS. 8 and 9, any number could beutilized to maintain the peripheral surface of the fixed drum at thepredetermined temperature, which is controlled by thermocouple 159.

The heat sealing means 146 further includes a freely rotatable hollowdrum 160 that is supported for rotation about a fixed axis defined by ashaft 161 rotatably supported in bearing structure 164 carried on thehousing of the machine. The freely rotatable drum 160 has a peripheralsurface 162 that is located in the path of movement of the rims and theweb 144 of foil is inserted between the periphery of the hollow drum 160and the container rims 58, as most clearly shown in FIG. 8. The drum 160is preferably formed to maximize heat transfer from the fixed drum 160to the foil web 144 while having some elastic characteristics. For thispurpose, the drum has an inner core 167 of aluminum with an outer sleeveof elastomeric material 168 such as silicon rubber. The heat suppliedfrom the fixed drum 150 will be transferred to the freely rotatable drum160 and heat the foil in the web 144 sufficiently to elevate thetemperature of the heat sealing material and produce a strong bondbetween the upper surface of the rims 58 and the foil. At the same time,the elastomeric material will accommodate some deflection of theperipheral surface relative to the container rims.

According to one aspect of the invention, the heat transfer between thefixed drum and the freely rotatable drum is increased by producing anirregular surface 166 on the periphery of the fixed drum 150 to therebyincrease the exposed surface area on the peripheral surface of the fixeddrum. Any manner of increasing the surface area may be utilized and, inthe illustrated embodiment, the irregular surface is shown as beingproduced by forming a thread on the peripheral surface 166.

While any type of heating element 156 may be utilized, the illustratedembodiment shows the elements as being electrical heating elementssupplied with current through a cord 170 that extends through a hollowrod 172 located above the heating means 146. The hollow rod 172 alsoacts as a support for the upright 152.

In the particular machine illustrated in FIG. 2, two such heating means146 have been illustrated as being located at longitudinally spacedlocations along the path defined by conveyor means 32. In the specificapparatus shown, the second heating means 146 is located downstream ofthe severing mechanism (to be described later). It will be appreciatedthat the location of the second heating means could be in juxtaposedrelation to the first heating means and, also in some instances, thesecond heating means could be eliminated.

Summarizing the web applying means, the roll of foil is freeely rotatedon the shaft 42 and is drawn into the path by the leading portion whichhas already been connected to the container rims so that the driving ofthe conveyor means will automatically draw the web 144 from the roll 140at the speed or rate at which the conveyor means is moving. In order toinsure that the web remains taut, it may be desirable to connect anadjustable brake (not shown) to the end of the shaft 142 so that apredetermined tension may be maintained on the web 144.

CUTTING STATION

The cutting station 42 for sequentially severing a continuous web ofmaterial is most clearly shown in FIGS. 4 through 7 and consists of asubstantially circular member 180 that is driven by the common drivemeans (not shown) for the machine through a shaft 182 rotated on thehousing of the apparatus 30. The connection between the shaft 182 andthe circular member or hollow drum 180 is made through a plurality ofbolts 184 that extend through the elongated slots or openings 186 in theend 188 of the drum. The elongated openings 186 allow for accuratepositioning of the cutter blades (to be described later) with respect tothe conveyor means 32.

Circular member 180 has a plurality of circumferentially spaced axiallyextending recesses 190 on the peripheral surface thereof and at leastone circumferential recess 192. The number of recesses 192 will dependupon the number of rows of openings in conveyor means 32, and the numberof recesses 190 depends upon the circumference of drum 180, the size ofthe containers being filled and the spacing of the containers on theconveyor means. The axially extending recesses 190 (FIG. 7) each have aplanar wall 194 that is parallel to and offset from a radius of the drum180, and recesses 190 each have an opposed wall 196 that has at least aportion 198 of which is outwardly inclined with respect to the planarwall 194. A cutting blade 200 is inserted into each recess 190, with onesurface of each blade engaging a planar wall 194 of the recess. Theinner edge of each blade 200 is seated on the base of the recess 190,and its cutting edge 202 extends beyond the periphery of the drum 180.Each blade 200 is held in a recess 190 by a wedge element 204 that has aplanar surface 206 engaging the opposite surface of the blade 200 and anopposite surface 208 which has an inclination that corresponds with theinclination of the outwardly inclined portion 198. Blades 200 arereleasably retained within the recesses 190 by releasable retainingmeans in the form of bolts 209 that extend radially of drum 180 andthrough openings in the wedge element. The threaded bolts 209 force thewedge elements towards the base of the recesses and hold the blades 200against the planar walls 194. This arrangement greatly simplifies theremoval and replacement of the blades with respect to the drum 180. Inthe illustrated embodiment, where only two side-by-side rows ofcontainers are filled, wedge elements 204 are provided with a recess inthe midportion, and these recesses have an inclined bottom surface 204a(FIG. 5) to provide a clearance for the vertical cutting means describedbelow.

The circumferentially extending recess 192 is identical incross-sectional configuration to recesses 190, with the planar wall 194thereof extending perpendicular to the axis of the drum 180. Thevertical cutting means includes a plurality of circumferential bladesegments 210 that are releasably retained in the recesses 192 by wedgeelements 212 similar in cross-sectional configuration to the wedgeelements 204. Blade segments 210 include an arcuate inner edge 210a(FIG. 5) that seat upon the base of recess 192, and an inclined endportion 210b that is positioned in spaced relationship with respect towedge surface 204b.

In order to insure that the blades 200, 210 completely sever the web 144into rectangular cover structures 62, endless conveyor means 32preferably has transversely extending recesses 214 (FIG. 6) andlongitudinally extending recesses 216 that are respectively aligned withthe blades 200 and 210 so that the blades may be moved below the uppersurface of the conveyor and completely sever the web.

FIRST FOLDING STATION

The first folding station 44 is shown in detail in FIGS. 10 and 11 andincludes first means for initially folding the cover portions extendingbeyond the rims of the containers downwardly while the containers aremoving along the path. The first folding station includes first foldingmeans consisting of a support 220 that is located below conveyor means32 and support 220 maintains the rims of the containers above the uppersurface of the conveyor means.

The configuration of the support 220 is shown in side elevation in FIG.2 and consists of a ramp that has a first portion 222 for initiallyengaging the bottoms of the containers as they are moving along thepath, an inclined portion 224 which raises the upper rims of thecontainers above the conveyor, a third portion 226 located in the firstfolding station 44, a further upwardly inclined portion 228 between thefirst and second folding stations 44 and 46 and a final flat portion 230in the area of the second folding station. The first inclined portion224 thus raises the container rims from a supported position on theconveyor means to a second position where the rims are spaced above theupper surface of the conveyor means at the first folding station 44.

The first means in the first folding station also includes plunger means240 for engaging the covers beyond the rims of the containers and drivemeans 242 for moving the plunger means in a generally arcuate or closedloop path above the conveyor means.

The drive means 242 consists of first and second shafts 244 that arerotatably supported by bearing structures 246 in the housing of thepackaging apparatus 30. The outer ends of the shafts 244 each have agear 248 secured thereto and each gear 248 is in mesh with an idler gear250. The lower shaft 244 is driven through a drive sprocket 252 from thecommon drive means (not shown) so that both shafts 244 aresimultaneously rotated in the same direction at the same speed.

The opposite ends of the respective shafts 244 each have a member 256secured thereto with each member having an opening 258 eccentric withrespect to the shaft 244. An elongated plate 260 has a pair ofvertically spaced openings 262 that each receive a bolt 264, and thebolts are threaded into the openings 258. The openings 262 and the bolts264 are configured to allow relative rotation between the plate 260 andthe bolts 264.

A support structure is secured to the plate 260 and consists of a rod266 secured to the lower portion of the plate 260 through a bolt 268. Anupper rod 270 is likewise secured to the plate 260 through a bolt 272.The outer ends of the two rods are interconnected through a furtherplate 274.

Plunger means 240 for each row of containers is carried by the supportstructure and consists of a hollow circular member 280 that is carriedby the lower rod 260 and has a lower edge 282 conforming generally tothe configuration of the periphery of the rim 58 on the container 34. Asmost clearly shown in FIG. 11, the hollow member 280 has an upwardly andinwardly inclined surface 284 so that the lower edge 282 initiallyengages the cover structure 62 slightly outwardly of the container rimand the inclined surface defines an inclined ramp to positively move thecover structure extending beyond the rim of the container to thedownward position shown in FIG. 10.

The folding mechanism further includes an inner or plunger member 290supported for reciprocal movement with in the outer member 280. Theinner plunger member 290 engages container cover structure above the rimand further insures that a proper bond has been produced between thefoil and the adjacent surface of the container rim. The inner hollowmember 290 has an elongated opening 292 through which rod 266 extendsand the elongated opening allows for the reciprocal movement of theinner plunger with respect to the outer member or plunger 280.

The inner plunger 290 is resiliently biased towards the path by biasingmeans in the form of a spring 293 having an upper end in engagement withthe rod 270 and a lower end engaging a sleeve 294 that is threaded on abolt 296 which extends through an opening in inner hollow member 290 andan opening in rod 270. With this arrangement, the spring 293 exerts adownward force on the inner hollow member or plunger to produce abonding force between the foil and the container rim.

Summarizing the first folding mechanism, the drive means 242simultaneously drives the plunger means 240 in a circular path throughthe positions illustrated in FIGS. 11 and 12. By properly synchronizingthe speed of rotation of shafts 244 with the speed of conveyor means 32,the lower edges 282 of the hollow members 280 are verticallyreciprocated into and out of engagement with the foil outwardly of therims of the containers simultaneously being moved along the path at thesame speed as the containers. Again, the arrangement of the firstfolding mechanism is such that the folding mechanism can readily beadapted to the speed of the conveying mechanism.

SECOND FOLDING STATION

The second folding station 46 incorporates second means for engaging theinitially folded covers which are in the position shown in FIGS. 10 and14 to a finally folded position where the peripheral edge of the coveris below the rim and in engagement with the side of the container. Thesecond folding means is most clearly shown in FIGS. 13 and 14 anincludes fixed rails 300 which are supported on a pair of transversemembers 302 located above the path (only one being shown) with eachfixed rail being located on one side of a row of containers. The secondfolding means further includes moving belt means in the form of anendless V-shaped belt 304 that is entrained about drive pully 306 (FIG.2) and driven pulley 308 supported for rotation about a fixed axis on asupport structure 310. The movable belt means is located between thespaced fixed rails 300 and the spacing between adjacent edges of thebelt means and the adjacent surface of the fixed rail is less than thediameter of the rims of the containers. The belt 304 is maintained in afixed horizontal plane aligned with the fixed rails 300 through a guidesupport member 316.

In operation, drive pulley 306 is driven through sprocket 312 from thecommon drive means in synchronized relation with the speed of theconveyor means. The conveyor means 32 moves the containers from thefirst folding station 44 upwardly along inclined portion 228 of ramp 220so that the rims 58 of the containers are located above the fixed rails300. Thereafter, the continued movement of the containers by the endlessconveyor means 32 will move the containers off the end of the ramp 220so that the containers are supported at opposite sides below the edgesof the rim 58. Since the endless belt 304 acts as a movable railengaging one side of a container, the opposite side of which is inengagement with the fixed rail 300 the containers will continue theirmovement along the path by the driving of the movable rail or endlessbelt and will simultaneously be rotated by being rolled along the fixedrails. During this rotation or rolling movement along the fixed rail,the weight of the container and product will hold the lower edges of thecontainer rims in engagement with the circular fixed rails 300 and willautomatically fold the periphery of the cover 62 under the rim and inengagement with the side walls of the containers. In order to insurethat the containers are maintained in engagement with the rails 300, itis desirable to have fixed guide means 316 located above the containersand centrally positioned between the fixed rails and the movable rail.The guide means 316 may have an upwardly inclined arcuate portion 318adjacent the inlet end of the second folding station to insure that thecontainers are moved downwardly into in engagement with the rails andendless belt means.

SUMMARY

The method of the present invention will be described in connection withthe brief summary of the operation of the apparatus that has beendescribed above.

When the common drive means for the entire apparatus is actuated,conveyor means 32 begins its motion and a container 34 is simultaneouslyreleased from each of the respective stacks of nested containers abovethe moving conveyor for deposit by gravity into the openings in theconveyor. The negative pressure created in the respective chambers 124below the conveyor below the conveyor means positively draws thecontainers into the opening with the lower surfaces of the rims engagingthe upper surface of the conveyor.

The supported containers are then moved along the path into the fillingstation where the first filling means 130 places one-half of the desiredamount of product into the container as it is moved below the nozzles134, and the second filling means 130 completes the filling operation.The containers then move to the cover applying station where thecontinuous web 144 of cover structure is heated by the heating means 146and automatically bonded to the upper surface of the container rims. Itshould be noted that the continuous web 144 of material is withdrawnfrom the roll 140, as needed, because the leading edge of the webdownstream of the first heating means 146 is already secured to thecontainer so that the conveyor means 32 draws the web of material fromthe roll.

The continuous web of material with the containers secured thereto isthen moved into the cutting station 42 where the web is severedlongitudinally annd transversely between each adjacent pair ofcontainers to produce a plurality of flat rectangular covers 62 as shownin FIG. 6. The individual containers and covers then may be passed undera further heating means 146 to further insure that the covers areproperly bonded to the upper surfaces of the container rims.

The continued movement of the containers by conveyor means 32 will thencause the bottom walls to engage the flat portion 222 of the rammp orsupport 220 and will cause the containers to move up the inclinedportion 224 onto the flat portion 226 of ramp 220 in the first foldingstation 46. As the containers approach the plunger means 240, theplunger means are in the position shown in the right hand portion ofFIG. 12 and the circular motion of the plunger means 240 willsimultaneously produce a downwardly component as well as a secondhorizontal component along the path, the latter of which is equal to thespeed at which the containers are moving along the path. The hollowmember 280 will automatically initially fold the rectangular covers sothat the periphery of each cover is located below the edge of theassociated rim, while the inner plunger 290 will be resiliently biasedinto engagement with the foil by the spring 293.

The moving conveyor will then cause the containers to move along thesecond inclined portion 228 of the ramp 220 and onto the flat portion230 located in the second folding station. At this time, the containersare supported on the flat portion 230 of the ramp 220 and are beingmoved along the path by the conveyor means 32. The rotational movementof the containers is initiated at this point by the moving belt 304.When the containers reach the end of the ramp, the weight thereof willcause the rims to be supported on the circular fixed rail 300 at oneside and be in engagement with the moving belt along the outer edge ofthe fixed rim. By proper synchronization of the speed of the moving belt304 with the conveyor means 32, the containers will be moved at the samespeed after they leave the conveyor means and will simultaneously berotated about their centers by being rolled along the fixed rails. Whenthe containers 34 reach the ends of the rails 300, they are deposited onfurther conveyor means 49 for futher packaging and shipment.

ALTERNATE EMBODIMENT OF CUTTING AND FOLDING STATIONS

In some instances it may be desirable to have the containers exitingfrom the packaging machine in interconnected groups of predeterminednumbers. This can readily be accomplished by slight modification of thesevering station 42 and the first folding station 44 as well as thedeletion of the second folding station 46.

The modified form of this invention is disclosed in FIGS. 17 through 20for producing interconnected groups of six containers shown in FIGS. 15and 16, each of which is connected to at least the two next adjacentcontainers.

The cutting station 42 is modified by replacing four of the sixtransversely extending cutting blades 200 with blades 350 that havefirst portions 352 that partially sever the web 144 at selectedlocations 354 shown in FIG. 15. The cutting blade 350 also has recessedsecond portions 356 located between the first portions 352 to perforatethe web 144 at 358 while maintaining a connection in this area betweentwo adjacent containers.

Likewise, the circumferentially extending blades 210 again have firstportions 360 for producing cuts 362 and recessed second portions 364 forproducing the perforations 366. The two continuous cutting blades 210will perform the same function as previously described and sever thewebs 144 from one edge to the other.

With this arrangement, the containers will emerge in six pack groupswith the cover structure being severed and scored or perforated as shownin FIG. 15. The severed portions of the web may then be folded down by amodified form of plunger means 240a (FIGS. 19 and 20) which is verysimilar to construction to plunger means 240, except that the hollowmember 280a has a plurality of cutout segments 370 remove from the loweredge 282a with the circumferentially spaced cutout segments 370 beingaligned with the unsevered portion or perforated portions 358 and 366.

With the alternate arrangement, the groups of six containers will emergefrom the apparatus 30 in the condition shown in FIG. 16 where therespective corners of the rectangular cover structures are foldeddownwardly below the rims of the containers while the perforated orscored portions of the web 144 maintain a connection between ajacentcontainers. The folding of the severed portions of the web produces aneat package and the openings defined in the respective adjacent groupsof four containers can readily be utilized for insertion of the fingerswhen the containers are ultimately used and are separated.

In either embodiment of the invention, the speed of the machine canreadily be adjusted to fit the desired needs. The speed can readily beincreased by increasing the amount of negative pressure created at thedispensing station and increasing the number of filling heads locatedalong each row in the filling station. The packages produced by themethod and apparatus of the present invention are extremely easy toopen, not only because of the relatively large, readily accessiblegripping tabs; but also because these tabs are serrated during the coversevering step, which makes them easy to grip and lift away from thecontainer side wall.

I claim:
 1. A package for storing a product comprising a plasticcontainer having a circular bottom wall and a side wall extendingupwardly therefrom with a circular rim extending outwardly from theupper end of said side wall, said rim defining a generally flat uppersurface having a circular peripheral edge, and a cover including arectangular flexible sheet of film having sealing characteristics on onesurface with said surface sealed to only said flat upper surface, saidsheet being formed of a material that is capable of taking on apermanent set and said sheet having a peripheral edge extending beyondsaid rim and being tucked around said circular peripheral edge of saidflat upper surface and under said rim, said rectangular sheet havinggenerally triangularly shaped corners extending substantially below saidrim and each corner being free from said container below said circularperipheral edge to define a gripping member for removing said cover fromsaid container to allow removal of said contents.
 2. A package asdefined in claim 1, in which the container rim is centered with respectto said rectangular sheet.
 3. A package as defined in claim 1 whereinsaid gripping portions are serrated.
 4. A package for storing a productcomprising: a plurality of spaced plastic containers, each containerhaving a circular bottom wall and a side wall extending upwardlytherefrom with a circular rim extending outwardly from the upper end ofsaid side wall, said rims lying in a common plane defining a generallyflat upper surface and each rim terminating in a circular peripheraledge; and a cover for said containers, said cover including arectangular flexible sheet of film having heat sealing characteristicson one surface with said surface sealed to said rims, said sheet beingselectively severed between said containers to provide flap portions,,the unsevered portions of said sheet providing connecting webs forretaining said containers in association as a unit, said sheet beingformed of a material that is capable of taking on a permanent set andthe flap portions of said sheet defining a peripheral edge extendingbeyond each rim and being folded around said circular peripheral edgesof said flat upper surfaces and downwardly relative to said rims to formgenerally triangularly shaped corners extending substantially below saidrim and each corner being free of the adjacent container side wall todefine a gripping member for removing said cover from said container toallow removal of said contents.
 5. A package as defined in claim 4wherein the unsevered portions of said sheet are perforated tofacilitate removal of individual containers from said package.
 6. Apackage as defined in claim 4 wherein said gripping portions areserrated.
 7. A package for storing a product comprising a containerhaving a bottom wall and a side wall extending upwardly therefrom with arim extending outwardly from the upper end of said side wall, said rimdefining a generally flat upper surface having a circular peripheraledge, and a cover including a rectangular flexible sheet of film havingheat sealing characteristics on one surface with said surface sealedonly to said flat surface, said sheet being formed of a material that iscapable of taking on a permanent set and said sheet having a peripheraledge extending beyond the circular peripheral edge of said upper surfaceand being tucked around said circular peripheral edge, said rectangularsheet having generally triangularly shaped corners extendingsubstantially below said rim and each corner being free from saidcontainer side wall below said circular peripheral edge to define agripping member for removing said cover from said container to allowremoval of said contents.